Heating method and apparatus



I J. F. MELZER HEATING METHOD AND APPARATUS June 18, 1963 2 Sheets-Sheet1 Filed July 2, 1959 INVENTORY JUL [/5 F. MELZER nu n u HHIHIIIHHHHMH Nu A1 TORNEY June 18, 1963 J. F. MELZER 3,094,230

HEATING METHOD AND APPARATUS Filed July 2, 1959 2 Sheets-Sheet 2 Fig-3ATTORNEY United States Patent 3,094,280 HEATING METHOD AND APPARATUSJulius F. Melzer, 544 King St., Port Chester, N.Y. Filed July 2, 1959,Ser. N0.824,578 2 Claims. (Cl. 236-93) My present invention rel-ates towater heating and has, as a general object, the prevention of thermalshock to boilers. My invention is especially useful for largeinstallations such as forced hot water heating systems for schools,hospitals, apartment houses, zoned heating systems, etc.

In 'such installations, distant heat radiating units are connected to alarge central boiler by way of long lines or connecting pipes. Althoughfor heating purposes, but water boilers are, in general, designed for a20 F. temperature differential between outlet and inlet water flow,boiler operators, in order to bring heat up more quicloly have beenknown to increase water circulation to a point such that the water flowis 30 to 50 times greater than the heat input to, or heating capacityof, the boiler. 'As a result, the boiler is often subjected to acomplete change of Water in as little as two minutes. Accompanying thisrapid change in water, is a sudden temperature drop of as much as 150F., giving rise to thermal shock in the boiler. This thermal shock isproductive of severe stresses, violent and powerful enough to loosentubes, crack plates and generally damage the boiler. The damage isaggravated in highly efficient boilers and is also more pronounced incases wherein there is inadequate water treatment. In the latterinstance, scale tormations cause still greater uneven contractions inthe steel of the boiler with attendant cracking. To overcome thesedifficulties is a further object of my invention. In effiecting thisobject, I provide for initial circulation of water flow through theboiler, when started up, that is restricted or limited to a safe valuewithin the heat recuperativ e capacity of the boiler. As the temperaturethroughout the system increases, my invention provides for automaticincrease in water flow without exceeding a safe temperaturedifiie-rential between the inlet and outlet of the boiler. In otherwords, my invention reduces the possibility of thermal shock byadmitting water to the boiler at a controlled rate which is matched bythe recuperative capacity of the boiler, the relation of the feed anddischarge Water temperature of the boiler being thermostaticallycontrolled and narrowed down to a safe temperature ditferential at alltimes. This desirable condition also follows, with my invention, whenfull water flow, productive of a large amount of heat radiation, isestablished.

More specifically, I provide a restrictive orifice or limiting openingwhich, despite the pumping capacity in the system, admits approximatelythe pounds of water per minute equivalent to the heat input to theboiler. I also provide a thermostatically controlled arrangement forpermitting greater water flow through the boiler as it absorbs heat andas the circulated water rises in average temperature. This controllingapparatus is mounted in such a Way as to be unresponsive to radiant heatfirom the boiler or to the boiler temperature but is responsive,however, substantially only to the temperature of the circulating water.Further, in accordance another fieature of my invention, means areprovided to enable inspection and repair of the control apparatuswithout removing water from the heating system.

My invention will be described hereinafter in greater detail with theaid of the accompanying drawing wherein:

FIG. 1 is a crosstsectional view of a hot Water boiler and shows thegeneral positioning and relationship of the elements of my invention forpreventing thermal shock to a boiler by circulating water;

Patented June 18, 1963 FIG. 2 is an end view of FIG. 1 taken on the line1-1;

FIG. 3 is a top plan view of metering apparatus which limits andrestricts water flow through the boiler of FIG. 1 at low temperaturesdespite the water pumping pressure in the system and permits increasedflow as the temperature of the circulating water increases;

FIG. 4 is a sectional view of the apparatus of FIG. 3 taken on the lineB-B;

FIG. 5 is a sectional view 0t FIG. 3 taken on line O-C;

A FIG. 6 a sectional view of FIG. 5 taken on the line FIG. 7 a plan viewof a special valve part or ele ment especially adapted for my inventionas embodied in part, in FIG. 5; and

FIG. 8 is a view, partly in seotionyof a modified form of water flowcontrol apparatus which limits water fio-w at low temperatures, despitepumping pressure, and automatically admits more Water to the boiler, orpermits increased circulation or flow only the temperature of thecirculating water increases.

Referring to FIGS. 1 and 2, I have illustrated a water heating, Scot-chmarine type, return tubular boiler 2 having a firebox or combustionchamber 4. A suitable thermostatically controlled oil burner,diagrammatically illustrated at 6, is mounted Within the firebox. Theproducts of combustion of burner 6 travel down the hollow central,cylindrical portion 8, forming part of the combustion chamber of theboiler, and return through fire tubes 10 to the smoke box 12. The smokebox 12 is provided with an outlet or stack 14 for connection to achimney. The paths of the smoke, fire and other products of combustionare indicated diagrammatically in FIG. 1 by arrows 16, 18, 20 and '22.

Water is returned to the boiler from distant heating units such asradiators (not shown), through return line 33 by the action of a waterpump P. The pump drives Water through the unit B, which will bedescribed in greater detail later, back into the boiler. Unit B, acts tolimit or meter the feed or return water flow into the boiler by means ofa restrictive orifice. At the beginning of heating operations, thisrestrictive orifice retards and restricts boiler water feed to the heatrecuperative capacity of the boiler or to the fuel heat input deliveredby the burner at the start of heating operations. Additional means areprovided within unit B, as will be described more fully later,thermostatically responsive to the relation of the water feed and waterdischarge temperatures so as to maintain a narrow, predeterminedtemperature differential between the same while increasing water flow,until full flow is established.

The thermostatic valve unit B, containing a restrictive orifice and athermostatically controlled orifice, is mounted on a curved feed pipe orcooling Water leg 26 Which acts to heat insulate or isolate valve unit Bfrom the heat of the boiler thereby providing a more stable ambienttemperature condition for unit B. In other words, leg 26 affords ameasure of separation from and reduces the influence of boiler heat fromafiecting the operation of unit B.

Water, returning to the boiler by way of return pipe 33, pump P, returnline section 31, unit B and curved leg 26, is introduced and fed intothe boiler Water through the openings 28 at the extreme left hand end ofthe closed off feed line 30 as shown in FIG. 1 suitably mounted, fixedWithin, or otherwise made integral with boiler 2. Feed line 30 tempersthe water and feeds it into the boiler at points 28 which are remotefrom the water outlet 32 located in the water back section 34 located atthe opposite end of the boiler. In brief, the internal feed line 30provides a more uniform tempering of the inlet water to the boiler andcarries the inlet or feed water to the end of the boiler which is remotefrom and opposite to that of the water discharge or outlet 32 of theboiler.

The unit B, which limits water flow into the boiler to a value whichfalls well within the recuperative heat input to the boiler and admitsmore water to the boiler as the circulated water in the system increasesin temperature, while, however, maintaining a safe temperaturedifferential between water input and output of the boiler, isillustrated in greater detail in FIGS. 3 to 8 inclusive, to whichspecific reference is now made.

As best seen in FIGS. 4 and 5, the water flow controlling unit isprovided with a cast iron or steel casing 40 having a water inletconnection 42 to which water is fed from the pump P of FIG. 1. An outletor discharge port 44, is provided from which controlled water flowthrough the unit passes into the leg 26 of FIG. 1. Inlet and outletports 42, 44 are at right angles to each other and are provided withconnecting flanges 43 and 45.

Cam operated valve heads 49, 50 are integrally provided to shut off aspace Within casing or housing 4% which contains the flow controllingequipment, so that the latter may be inspected and adjusted throughaccess door 110, which may be removably bolted in place. Threadedopening 54, in axial alignment with opening 42, is provided with aclosing off or plug member (not shown). This plug should be removed tolet out water in the shut off space, before the access door 110 isremoved.

Normally with the valve heads 49, 50 in their open positions as shown inFIG. 5, water flows or is pumped into the casing 40 through inlet 42.Water then flows through the conical knife edge openings 46, provided inthe valve head 48, into the lower space 60 of casing 40. The water thenpasses through the open valve to the outlet port 44. It should be notedthat the sharp edged openings 46 in the valve head 48 are aligned withopenings 62 in the supporting valve part or base 64. A plan view of thisvalve part or valve base 64 is given in FIG. 7. The arrangement is suchthat the openings 62 are aligned with the sharp edged openings 46 in thevalve head 48. The valve part 64 is provided with a shoulder 66 so as tofirmly and relatively fixedly engage and be supported by cooperatingshoulders 68 carried by and made integral with housing 40.

The orifices or holes 46 are designed to restrict the flow of watertherethrough to a safe value well within the heat recuperative power ofthe boiler when it is started up. The orifices 46 therefore, restrict,limit, meter or control the flow of circulating water, despite thestarting up capacity of the pump P brought about by a demand forincreased heating by the distant heating units. In this way, myinvention prevents the injection of a large mass of cold water into theboiler at such a rate as would cause damage to the boiler.

As the temperature of the water in the boiler increases, I haveprovided, also in accordance with my present invention, means forautomatically increasing the amount of water admitted or fed to theboiler, and therefore, the circulation of water, until full water flowor circulation is established. This increase in flow is only carried outand permitted, according to my invention, while maintaining a safediflerential in temperature between inlet and outlet water for theboiler. As best seen in FIGS. 4 and 5, the means for accomplishing theforegoing, is in the form of the temperature operated orthermostatically operated bellows system 70, mounted within a support72, carried by the valve part 64. This bellows is filled with a suitabletemperature responsive fluid which expands with increase of temperature.The end result of the expansion of the bellows is to drive the valvesupporting rod 74 upwardly against the normal valve closing action ofhelical safety spring 76. As a result, the rod 74, to which valve head48 is attached, raises the latter and permits additional water flowaround the valve head bevelled edge 80 (see FIG. 4), and through theadditional openings 82 (FIG.

4 7) provided between the cross arms 83, 85, of the valve part 64 (FIGS.4 and 5).

The apparatus is so designed that when the temperature of the Watercirculated through the unit B has the greatest temperature differentialbetween the outgoing and incoming water, the only water that can becirculated through this unit B and the boiler will be through theorifices 46 and openings 62 (FIG. 4). This circulated amount would thenbe the equivalent to the fuel thermal input to the boiler. Excess Watercirculated by reason of the capacity of the pump P is by-passedexternally to the system. As the circulated water through the orificesbecomes heated, the valve 48, attached to the thermostatic element 70,is expanded, allowing a greater capacity flow through unit B until thedifferential is reduced and the temperatures become so close that thethermostatic valve has opened to its maximum opening and the full pumpcapacity will then be circulated throughout the system.

If it is desired to inspect the fixed orifice 46 and/or the thermostaticelement 70-72-76 with its valve 48; the disc valves 49 and 50 are firstclosed by rotating shafts -92 (FIGS. 4 and 5). Shaft 90 rotates the camelement 94, fastened thereto (see FIG. 4) to an open or shut position asdesired. Similarly, cam 96 (FIG. 5) is driven by shaft 92 to open orshut valve 50. Pointers 98, are provided to indicate whether valves 50and 49 are closed or open. These valves are provided with guidingspiders 102, 104, as shown in FIG. 5. With earns 94 and 96 driven by theshafts 90 and 92 to the closed positions, access door may be removed asfor example by removing bolts or other fastening means (not shown).Before removing the access door 110, the plug (not shown), in screwthreaded opening 54 should be unscrewed to remove the trapped water inthe space within housing 40 between cut off valves 49 and 50. Themetering equipment including valve 48 and thermostatic controllingelements 70, 76 will, upon removal of door 110, be accessible forinspection and adjustment.

To summarize, the unit B, as described, constitutes a metering unitwhich, by virtue of the sharp edged conioally shaped orifices 46, limitswater flow through the system, when valve head 48 is in its lowermostposition, so as to be effectively restricted to the heat input of theburner or the heat recuperation of the boiler. The water circulation ispermitted to increase only when a predetermined temperature differentialexists between boiler inlet and outlet by the action of thermostaticallycontrolling apparatus 70, 76.

The integral valve cutoffs 49, 50 permit retention of the water in theboiler and throughout the heating system while allowing access to thethermostatic control and other elements within housing 40. The unit B ismounted on a cooling or tempering water leg or pipe 26 spaced from theboiler so as to prevent boiler heat from affecting the thermostaticcontrol element within housing 40. My improved system also contemplatesthe use of an integral, boiler tempering, water feed 30 from the coolingleg 26 to the end of the boiler opposite to and remote from thedischarge end 32 or water outlet or output end of the boiler.

In FIG. 8, I have illustrated another form of fiow controlling ormetering unit. As shown, water flows into the unit through the input end200 thereof and out through outlet 202. Coupling flanges 204, 206 areprovided for connecting input and Output water pipes thereto. The casing208 has, integral therewith, a web 210 and a base or bottom 212. Asshown, one or more hollow cylinders 214 are carried by the base 212 andextend through suitable openings in web 210. Each of the cylinders 214is provided with a fixed water flow orifice or opening 216. These fixedorifices 216 have sharp edges and limit the .water flow through thesystem to a safe value when the system is started up. The water flowingthrough the fixed openings 216 reaches the outlet 202 through the slotsor other side openings 220 in the hollow walls of the cylinders 214. Theopenings 220 are located below web 210 as shown. Also, one or morethermostatically controlled valves 230 are provided in the arrangementof FIG. 8. These elements 230 are diagrammatically illustrated in FIG. 8and are supported by the base 212 in any suitable way. As thetemperature of the Water through the system increases, thermostaticelements 230 permit additional water flow until full flow isestablished. The thermostatically controlled valves 230 of FIG. 8 arepreferably of the type described in FIGS. 4 and and each makes use of abevelled valve head 48, thermostatic bellows 30 and a safety closingspring 76. These springs, it should be noted, close the thermostaticallyoperated valves, should they become defective, as for example, throughloss of temperature responsive operating fluid.

Although not illustrated in FIG. 8, there may be used, integral with theinput and output sections 208, 210, disc cutoif valves such as 49, 50 ofthe type shown in FIGS. 3 and 4. Instead of the access door 110 shown inFIGS. 4 and 5, the units are made as integral parts, the orifice units214 and the thermostatic elements 230 are self contained and areinserted in the bottom of container or housing 208. The cutolf valves 49and 50 are the same as shown in FIGS. 4 and 5 and, as shown in FIG. 8are provided with indicators 100 and 98.

Although I have described my invention in connection with the heating ofwater, it should be clear that the invention is also adapted and usefulfor the heating of other fluids. Hence, in the claims which follow, theterm water is intended to include such other fluids as lend themselvesto the use of my invention. Also, other changes within the scope of myinvention may be made without deviating from the spirit and scopethereof, as for example, other types of boilers may be employed, castiron, steel, brass, or other material may be used tor the housings, andso on.

Having thus described my invention, what I claim is:

1. -A water flow controlling unit comprising a metal casing, having awater inlet connection and a water outlet connection, arranged at tightangles to each other; a re movable plug in the casing opposite the inletconnection; disc valves integral with the casing for shutting off thespace between the inlet and outlet connections, an access door in saidcasing leading to said shut off space; a valve in the shut oif space ofsaid casing having a perforated disc valve head and a stem mountedwithin said casing in alignment with said inlet opening, theperforations in said head having sharp edges, a valve seat carried bysaid casing against which said valve head closes, a safety springsurrounding said valve stem for normally closing said valve head againstsaid valve seat; a valve pant mounted beneath said valve head, said parthaving cross arms with openings in the cross arms aligned with theperforations in said valve head and a temperature responsive bellows,supported by said valve pant, connected to said valve stem for movingsaid valve stem against said safety spring and thereby separating saidvalve head from said valve seat and valve part.

2. A Water flow controlling unit comprising a metal casing, having awater inlet connection and a water out let connection; a removable plugin the casing opposite the inlet connection; disc valves adjacent theinlet and outlet connections mounted within the casing for shutting 01fthe space between the inlet and outlet connections, an access door insaid casing leading to said shut off space; a valve having a perforateddisc valve head and a stem mounted within said casing in said shut oflspace in alignment with said inlet opening, the perforations in saidhead having sharp edges, a valve seat carried by said casing againstwhich said valve head closes, a safety spring surrounding said valvestem for normally closing said valve head against said valve seat; avalve part mounted beneath said valve head, said part having cross armswith openings in the cross arms aligned with the perforations in saidvalve head and a temperature responsive bellows, supported by said valvepart, connected to said valve stem for moving said valve stem againstsaid safety spring and thereby separating said valve head from saidvalve seat and valve part.

References Cited in the file of this patent UNITED STATES PATENTS1,406,922 'Boyce Feb. 14, 1922 1,806,530 Giesler May 19, 1931 1,880,539Wald Oct. 4, 1932 2,081,831 Moore May 25, '1937 2,086,360 Hill July 6,1937 2,340,844 Dillman Feb. 1, 1944 2,461,136 Bomquist Feb. 8, 19492,895,496 Sanctuary July 21, 1959

1. A WATER FLOW CONTROLLING UNIT COMPRISING A METAL CASING, HAVING AWATER INLET CONNECTION AND A WATER OUTLET CONNECTION, ARRANGED AT RIGHTANGLES TO EACH OTHER; A REMOVABLE PLUG IN THE CASING OPPOSITE THE INLETCONNECTION; DISC VALVES INTEGRAL WITH THE CASING FOR SHUTTING OFF THESPACE BETWEEN THE INLET AND THE OUTLET CONNECTIONS, AN ACCESS DOOR INSAID CASING LEADING TO SAID SHUT OFF SPACE; A VALVE IN THE SHUT OFFSPACE OF SAID CASING HAVING A PERFORATED DISC VALVE HEAD AND A STEMMOUNTED WITHIN SAID CASING IN ALIGNMENT WITH SAID INLET OPENING, THEPERFORATIONS IN SAID HEAD HAVING SHARP EDGES, A VALVE SEAT CARRIED BYSAID CASING AGAINST WHICH SAID VALVE HEAD CLOSES, A SAFETY SPRINGSURROUNDING SAID VALVE STEM FOR NORMALLY CLOSING SAID VALVE HEAD AGAINSTSAID VALVE SEAT; A VALVE PART MOUNTED BENEATH SAID VALVE HEAD, SAID PARTHAVING CROSS ARMS WITH OPENINGS IN THE CROSS ARMS ALIGNED WITH THEPERFORATIONS IN SAID VALVE HEAD AND A TEMPERATURE RESPONSIVE BELLOWS,SUPPORTED BY SAID VALVE PART, CONNECTED TO SAID VALVE STEM FOR MOVINGSAID VALVE STEM AGAINST SAID SAFETY SPRING AND THEREBY SEPARATING SAIDVALVE HEAD FROM SAID VALVE SEAT AND VALVE PART.